Fast battery charging system and method

• US 5,463,305 A
• Filed: 02/18/1992
• Issued: 10/31/1995
• Est. Priority Date: 06/07/1982
• Status: Expired due to Term

• Current Assignee: Intermec IP Corporation (Honeywell International Inc.)
• Original Assignee: Norand Corporation (Baker Hughes Company)
• Inventors: Koenck, Steven E.
• Primary Examiner(s): Peckman, Kristine L.
• Application Number:
  US07/837,650
• Time in Patent Office: 1,351 Days
• Field of Search: 320/21, 320/22-24, 320/31, 320/32, 320/35, 320/36, 320/39, 320/40, 320/43, 320/44
• US Class Current: 320/145
• CPC Class Codes: G01R 31/3648 comprising digital calculation means, e.g. for performing an algorithm
• CPC Class Codes: G01R 31/374 with means for correcting the measurement for temperature or ageing
• CPC Class Codes: G01R 31/3842 combining voltage and current measurements
• CPC Class Codes: G06F 1/263 Arrangements for using multiple switchable power supplies, e.g. battery and AC G06F1/30 takes precedence
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01M 6/5044 Cells or batteries structurally combined with cell condition indicating means
• CPC Class Codes: H01M 6/505 Cells combined with indicating means for external visualization of the condition, e.g. by change of colour or of light intensity
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00038 using passive battery identification means, e.g. resistors or capacitors identification by mechanical connections H02J7/0045
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: H02J 7/0049 Detection of fully charged condition
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/0069 : Charging or discharging for charge maintenance, battery initiation or rejuvenation
• CPC Class Codes: H02J 7/0071 : with a programmable schedule
• CPC Class Codes: H02J 7/00711 : with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/00712 : the cycle being controlled or terminated in response to electric parameters
• CPC Class Codes: H02J 7/00714 : in response to battery charging or discharging current
• CPC Class Codes: H02J 7/007194 : of the battery
• CPC Class Codes: H02J 9/061 : for DC powered loads
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

In an exemplary fast charging system, a hand-held computerized terminal with rechargeable batteries therein may be bodily inserted into a charger receptacle. The terminal may have volatile memory and other components requiring load current during charging. The system may automatically identify battery type and progressively increase charging current while monitoring for an increase in battery terminal voltage to ascertain the level of load current. The battery temperature may be brought into a relationship to surrounding temperature such that by applying a suitable overcharge current value and observing any resultant temperature increase, the level of remaining battery charge can be determined. For example, if the battery is found to be relatively fully discharged, a relatively high fast-charge rate may be safely applied while monitoring battery temperature. If the battery is initially relatively fully charged or reaches such a state during fast charge, the system may automatically switch to a lower sustainable overcharge rate selected according to battery type and temperature. A preferred system may automatically recharge the battery of a portable device according to an optimum schedule of essentially maximum safe charging rates as a function of battery temperature. The system may also convert a regulated charging current to a pulsed and modulated waveform to provide efficient net charging to the battery. The source of charging current can optionally be placed outside the terminal housing to eliminate any heat dissipation effects of the current source.

Claims

1. A means for charging a battery contained within a housing of a device, where the battery is connected to a varying load and charging current for a given time is provided by charging current means, said battery charging means comprising:

connection means for communicating the charging current from the charging current means to the battery;

switching means positioned in the connection means for converting the charging current from the charging current means into a pulsed current consisting of successive pulses having a duty cycle and a net value of charging current for a given time;

monitoring means associated with the battery for sensing the net value of the charging current for a given time at the battery;

control means for receiving the net value of charging current at the battery for a given time, comparing it to a target net value for and adjusting operation of the switching means to vary the duty cycle of the pulsed current to maintain the target net value at the battery regardless of the varying load; and

said charging current means comprising a current regulation means to produce the charging current.

2. The means of claim 1 wherein the current regulation means is connected to an alternating current power source.

3. The means of claim 1 wherein the connection means includes a connection port on the housing of the device, a connector means associated with the charging means for releasable connection to the connection port on the housing, and an electrical conducting conduit to the battery.

4. The means of claim 1 wherein the switching means comprises a switching device which dissipates heat at a level which does not materially affect ambient temperature inside the housing of the device.

5. The means of claim 1 wherein the switching means comprises a switching device which varies the duty cycle of the pulsed current according to a control signal from the control means.

6. The means of claim 1 wherein the switching means comprises a transistor means.

7. The means of claim 1 wherein the switching means comprises a switching device which creates the pulsed current having pulses of variable pulse width.

8. The means of claim 1 wherein the monitoring means comprises a sensing component operatively connected to the battery to receive current corresponding to the net value of current received by the battery.

9. The means of claim 8 wherein the monitoring means includes an amplifying means for producing an amplified signal correlated to the net value of charging current to the battery.

10. The means of claim 9 wherein the control means includes an integrator means for integrating the amplified signal corresponding to the net value of charging current to the battery for a given time, the integrator means issuing a signal to a pulse width modulator means which sends a switching signal to the switching means correlated to a desired duty cycle for the pulsed current to maintain a minimum net charging current to the battery.

11. The means of claim 1 wherein the control means comprises a feedback component which issues a control signal to the switching means, the control signal determining the duty cycle of the pulsed current.

12. The means of claim 11 wherein the feedback component of the control means includes a comparator means for comparing the net value of charging current to the battery for a given time with a predetermined minimum net value, and for issuing the control signal to the switching means correlated to the difference between the net value of charging current for a given time and the predetermined minimum net value to determine the duty cycle of the pulsed current.

13. The means of claim 11 wherein the control means includes an integrator means and a pulse width modulator means.

14. The means of claim 1 wherein the switching means comprises a switching device which creates the pulsed current having variable width pulses of generally rectangular shape.

15. The means of claim 1 wherein the switching means comprises a switching device which creates the pulsed current having variable width pulses of generally trapezoidal shape.

21. The method of claim 1 wherein the repeating pulses of a defined duty cycle are variable width pulses of a generally rectangular shape.

16. A method of insuring a minimum level of charging current to a battery inside a housing of a device while minimizing heat dissipation inside the housing where the device draws a varying load from the battery comprising:

connecting the battery to a source of charging current located externally of the housing;

modifying the charging current between the source of charging current and the battery by pulsing the charging current in repeating pulses of a defined duty cycle;

continuously sensing the charging current at the battery;

determining net charging current to the battery for a given time; and

controlling the duty cycle of the repeating pulses by a pulse with modulator means to maintain at least a minimum level of net charging current to the battery.

17. The method of claim 16 wherein the charging current is produced at a level that substantially exceeds general current requirements for battery recharging and varying load of the device.

18. The method of claim 16 wherein the charging current is modified by utilizing a switching means to pulse the charging current in repeating pulses of varying duty cycles.

19. The method of claim 16 wherein the net charging current to the battery for a given time is sensed.

20. The method of claim 16 wherein the duty cycle of the repeating pulses is varied as a function of the net charging current to the battery for a given time.

22. The method of claim 16 wherein the repeating pulses of a defined duty cycle are variable width pulses of a generally trapezoidal shape.

23. The method of claim 16 wherein the repeating pulses of a defined duty cycle are generated in a generally trapezoidal shape to eliminate abrupt step-type changes in magnitude to reduce introduction of transients.

24. An apparatus for providing charging current to a rechargeable battery inside a housing of a device which presents a varying load to the battery during recharging comprising:

connection means for electrically communicating the device to a source of charging current which is located externally of the housing of the device;

conduit means for electrically communicating the connection means to the battery;

pass means operatively positioned in the conduit means between the connection means and the battery for selectively passing the charging current to the battery according to a control signal;

control means in communication with the battery and the pass means for monitoring the amount of the charging current received by the battery and generating the control signal based on the amount of the charging current received by the battery; and

so that the control signal can increase and decrease a net amount of the charging current passing the pass means for a given time to control the net amount of the charging current received by the battery for a given time.

25. The apparatus of claim 24 wherein the pass means comprises a pulsing means for modifying the charging current from the source of charging current to a pulsed charging current of selected pulse shape and duty cycle.

26. The apparatus of claim 25 wherein the pass means comprises a switching means.

27. The apparatus of claim 26 wherein the switching means produces generally square-wave pulses.

28. The apparatus of claim 26 wherein the pulsing means produces pulses of variable shape.

29. A method for providing adequate charging current to a battery without heat dissipation problems within a housing of a device, where the device presents a varying load to the battery during charging comprising:

providing a regulated charging current to the device from a charging current source located externally of the housing so that heat from the charging current source is dissipated outside the housing;

pulsing the regulated charging current to the battery so that the battery receives a net charging current over successive periods of time;

monitoring the net charging current for selected time intervals; and

adjusting the pulsing of the regulated charging current in a manner that provides adequate charging current to the battery regardless of varying load on the battery.

30. The method of claim 29 wherein the pulsing creates pulses of variable shape and duty cycle.

31. The method of claim 29 wherein the pulsing creates pulses of variable duty cycle.

32. The method of claim 29 wherein the net charging current for a selected period of time is derived by integrating the monitored charging current received at the battery for a given period of time.

33. The method of claim 30 wherein the net charging current to the battery is determined by the shape of the pulses of the charging current.

34. A means for charging a battery contained within a housing of a device, where the battery is connected to a varying load and charging current is provided by charging current means positioned externally of the housing, comprising:

connection means for communicating the charging current from the charging current means to the battery;

switching means positioned ill the connection means for converting the charging current from the charging current means into a pulsed current consisting of successive pulses having a duty cycle and a net value of charging current for a given time;

monitoring means associated with the battery for sensing the net value of the charging current at the battery; and

control means for receiving at the battery the net value of charging current for a given time, comparing it to a target net value, and adjusting operation of the switching means to vary the duty cycle of the pulsed current to maintain the target net value at the battery regardless of the varying load.

35. The means of claim 34 wherein the connection means includes a connection port on the housing of the device, a connector means associated with the charging means for releasable connection to the connection port on the housing, and an electrical conducting conduit to the battery.

36. The means of claim 34 wherein the switching means comprises a switching device which dissipates heat at a level which does not materially affect ambient temperature inside the housing of the device.

37. The means of claim 34 wherein the switching means comprises a switching device which varies the duty cycle of the pulsed current according to a control signal from the control means.

38. The means of claim 34 wherein the switching means comprises a transistor means.

39. The means of claim 38 wherein the transistor means comprises a high speed FET for reducing transients in response to input signals.

40. The means of claim 34 wherein the switching means comprises a switching device which creates the pulsed current having pulses of variable pulse width.

41. The means of claim 34 wherein the monitoring means comprises a sensing component operatively connected to the battery to receive current corresponding to the net value of current received by the battery.

42. The means of claim 41 wherein the monitoring means includes an amplifying means for producing an amplified signal correlated to the net value of charging current to the battery.

43. The means of claim 42 wherein the control means includes an integrator means for integrating the amplified signal corresponding to the net value of charging current for a given time to the battery, the integrator means issuing a signal to a pulse width modulator means which sends a switching signal to the switching means correlated to a desired duty cycle for the pulsed current to maintain a minimum net charging current to the battery.

44. The means of claim 34 wherein the control means comprises a feedback component which issues a control signal to the switching means, the control signal determining the duty cycle of the pulsed current.

45. The means of claim 44 wherein the feedback component of the control means includes a comparator means for comparing the net value of charging current for a given time to the battery with a predetermined minimum net value, and for issuing the control signal to the switching means correlated to the difference between the net value of charging current for a given time and the predetermined minimum net value to determine the duty cycle of the pulsed current.

46. The means of claim 44 wherein the control means includes an integrator means and a pulse width modulator means.

47. The means of claim 34 wherein the switching means comprises a switching device which creates the pulsed current having variable width pulses of generally rectangular shape.

48. The means of claim 34 wherein the switching means comprises a switching device which creates the pulsed current having variable width pulses of generally trapezoidal shape.

49. A method of insuring a minimum level of charging current to a battery inside a housing of a device while minimizing heat dissipation inside the housing where the device draws a varying load from the battery comprising:

connecting the battery to a source of charging current located externally of the housing;

modifying the charging current between the source of charging current and the battery by pulsing the charging current in repeating pulses of a defined duty cycle;

continuously sensing the charging current at the battery;

determining net charging current to the battery for a given time; and

controlling the duty cycle of the repeating pulses to maintain at least a minimum level of net charging current to the battery.

50. The method of claim 49 wherein the charging current is produced at a level that substantially exceeds general current requirements for battery recharging and varying load of the device.

51. The method of claim 49 wherein the charging current is modified by utilizing a switching means to pulse the charging current in repeating pulses of varying duty cycles.

52. The method of claim 49 wherein the net charging current to the battery for a given time is sensed.

53. The method of claim 52 wherein the duty cycle of the repeating pulses is varied as a function of the net charging current to the battery for a given time.

54. The method of claim 49 wherein the repeating pulses of a defined duty cycle are variable width pulses of generally rectangular shape.

55. The method of claim 49 wherein the repeating pulses of a defined duty cycle are variable width pulses of a generally trapezoidal shape.

56. The method of claim 49 wherein the repeating pulses of a defined duty cycle are generated in a generally trapezoidal shape to eliminate abrupt step-type changes in magnitude to reduce introduction of transients.